Surface structuring of case hardened chain pins by cold-sprayed microparticles to modify friction and wear properties

This paper presents the results of the application of a cold spray technique for structuring metallic surfaces with microparticles. The resulting changes in surface properties were characterized to observe their influences on the tribological behavior of the structured surface. The spray technique was applied to a technical component, a 16MnCr5 steel chain pin, designed to be mounted in a linear reciprocating tribometer. TiO₂ microparticles were used to structure the surface with a homogeneous distribution of singly dispersed particles, rather than a homogeneous closed coating on the surface. Tribometer tests were performed to directly compare structured and unstructured chain pins, and a significantly reduced sliding friction coefficient was observed for the structured pin. The pins were characterized in detail by surface analysis prior to and after application of the tribological load to set the surface parameters and surface chemistry, even on the microscale. It was confirmed that the particle structuring induced changes in the surface properties, and the durability of the changes after tribological loading was evaluated.     

中碳钢/不锈钢磁场摩擦中磨屑的行为和作用

以45钢销/302不锈钢盘摩擦副为研究对象,采用自制的销、盘摩擦磨损试验机,研究了直流磁场作用下磨屑在摩擦过程中的行为及其对摩擦磨损性能的作用. 为此分析了有、无磁场作用下磨屑在磨损面上的分布特点,利用扫描电镜观察了磨屑及45钢销磨损面的形貌,采用三维形貌仪表征了磨损面特征区域的相对高度. 与无磁场时的摩擦磨损情况相比,磁场作用下45钢销的磨损量有所增大,而摩擦系数稍有减小. 摩擦过程中出现了302不锈钢盘向45钢销的材料转移并形成了不连续的转移层,该转移层相对高度较大,承担了主要的摩擦磨损并趋于平滑. 磁场作用下45钢销磨损面吸附少量磨屑并使之细化和氧化,该吸附磨屑在一定程度上减小了摩擦副的摩擦系数,并阻碍试样之间的材料转移,从而增加了45钢销的磨损量.      

On the spray drying of uniform functional microparticles

Spray drying is a typical method to produce particles in dry powder forms at industrial scale.Most spray-dried products often show a wide range of particle properties even within the same batch.At Monash University,we utilise a microfluidic spray drying approach to generate uniform microparticles with tightly controlled characteristics and sizes in a scalable,almost waste-free process.The technique is useful to correlate the effects of formulation and spray drying conditions on the properties of spray-dried particles,and can be used to test new formulations for targeted applications such as encapsulation and release of active ingredients.The synthesis route can be applied to other self-assembling systems,including mesoporous,crystalline,and hierarchically structured microparticles.As spray drying is commonly used in commercial scales,the understanding of how functional particles are formed in relation to formulations and process conditions could assist in developing a cost effective,energy and material-efficient route to produce powders with better properties and ease of handling for more advanced applications such as selective adsorption and bio-separation.     

On the spray drying of uniform functional microparticles

Spray drying is a typical method to produce particles in dry powder forms at industrial scale. Most spray-dried products often show a wide range of particle properties even within the same batch. At Monash University, we utilise a microfluidic spray drying approach to generate uniform microparticles with tightly controlled characteristics and sizes in a scalable, almost waste-free process. The technique is useful to correlate the effects of formulation and spray drying conditions on the properties of spray-dried particles, and can be used to test new formulations for targeted applications such as encapsulation and release of active ingredients. The synthesis route can be applied to other self-assembling systems, including mesoporous, crystalline, and hierarchically structured microparticles. As spray drying is commonly used in commercial scales, the understanding of how functional particles are formed in relation to formulations and process conditions could assist in developing a cost effective, energy and material-efficient route to produce powders with better properties and ease of handling for more advanced applications such as selective adsorption and bio-separation.     

几种油性剂和极压抗磨剂对T8钢/Al2O3摩擦磨损性能的影响

采用Falex型摩擦磨损试验机考察了T8钢／Al2O3陶瓷摩擦副在3种油性剂(T405、T406和T451)与3种极压抗磨剂(T309、T306、T321)作用下的摩擦学性能；用扫描电子显微镜观察试销表面磨损状态；用俄歇电子能谱仪分析了摩擦表面元素化学成分。结果表明：3种油性剂都可以不同程度地改善摩擦副的摩擦磨损性能，其中尤以T405作用效果最佳；3种极压抗磨剂均具有较好的减磨抗磨性能，其中T309的抗磨性能最为突出，T321与T306可以明显降低摩擦系数，相比之下两者磨损率较大；俄歇电子能谱分析揭示在T309作用下，由于摩擦化学反应在T8钢试销磨损表面形成了含S、P物质层；油性剂作用下摩擦副的磨损形式主要为磨料磨损，而T309作用下磨损形式主要为磨料磨损与摩擦化学(腐蚀)磨损。     

不同气氛环境中钢/铜摩擦副的高速干滑动摩擦磨损特性研究

采用MMS-1G型高温高速摩擦磨损试验机研究了在氧气和二氧化碳2种气氛环境中CrNiMo钢/H96黄铜摩擦副的高速干滑动摩擦磨损特性,采用扫描电子显微镜和X射线光电子能谱仪对CrNiMo钢销试样的磨损表面形貌及其元素的化学状态进行分析,结合摩擦表面宏观温度的测量,分析了不同气氛环境中pv值对摩擦副摩擦磨损特性的影响.结果表明,在不同气氛环境中,摩擦副表现出完全不同的摩擦磨损特性,在二氧化碳气氛环境中,摩擦副的摩擦系数与CrNiMo钢的磨损率均高于氧气气氛环境中,这是由于2种气氛环境中的摩擦表面温度及其磨损机制的差异所致.二氧化碳气氛环境中的摩擦表面温度高于氧气气氛环境中的摩擦表面温度,其主要磨损机制为磨粒磨损、金属流变和粘着磨损;而氧气气氛环境中主要表现为氧化磨损和粘着磨损.     

An experimental method for evaluating the heat transfer coefficient of liquid-cooled short pin fins using infrared thermography

The aim of this research is to evaluate the convective heat transfer coefficient of liquid cooled short pin fins by means of the infrared thermography. An experimental apparatus was set-up to analyze single, in-line and staggered array configurations of short pin fins. In this work the attention is focused on single pins having different shapes: circular, square, triangular and rhomboidal. The infrared thermography is used to indirectly measure the lateral pin temperature by observing the upper surface temperature of radially heated pins; these are placed in a test section chamber equipped with a Zinc Selenide infrared window. Flow visualizations by means of ink tracers are also carried out to relate the thermal behavior with the flow field. Regressions by the Zukauskas correlation were performed for each shape and new coefficients were carried out; a comparison among the different pin geometries underlines a better thermal exchange for the triangular and rhomboidal pins.     

Investigation on convective heat transfer over a rotating disk with discrete pins

A three-dimensional numerical study on the flow and heat transfer characteristics over a rotating disk surface with discrete pins was conducted by the use of RNG k–ε turbulent model. And some experiments were also made for validation. The effects of rotating angular speed and pin configuration on the temperature maps and convective heat transfer characteristics on the rotating surface were analyzed. As the increase of rotating velocity, the impingement of pumping jet on the centre of rotating disk becomes stronger and the transition from laminar to turbulent occurs at the outer radius of rotating disk, which resulting in heat transfer enhancement. The pins on the disk make the pumping action of a rotating disk weaker. Simultaneously, they also act as perturbing elements to the cyclone flow near the rotating disk surface, making the overall heat transfer to be enhanced. The needle pins have higher convective heat transfer capacity than the discrete ring pins with the same extend pin areas.     

Distribution of the friction heat between two stationary pins and a rotating disc

A closed-form model for the computation of heat fluxes distribution between two motionless cylindrical pins and a fast rotating disc is investigated. Based on a finite Fourier transform technique and an asymptotic analysis, a series solution for the disc surface temperature is obtained. The solution for the pin is trivial. By matching the average temperatures over the contact areas the coefficients of the heat distribution between a pin and a disc are found. It is demonstrated that the present analysis covers the previously known case of one pin as well as new results are obtained. Received on 4 November 1996     

Bearing Load Measurement in a Hydropower Unit Using Strain Gauges Installed Inside Pivot Pin

To determine a machine’s mechanical condition it is of importance to know the radial bearing forces in the machine. Radial forces are caused by magnetic pull forces in the generator, clamped shafts, mass unbalance and flow properties around the turbine. Measuring the shaft displacement in the bearing or the bearing housing acceleration is not sufficient for status determination of a vertical hydropower unit. It is the magnitude and frequencies of the radial forces in combination with structure properties which give information as to whether a measured value is harmful or not. This paper presents an alternative method for measurement of radial bearing load in a hydropower unit. The method presented in this paper is based on strain measurements on pivot pins. The pivot pins are placed behind the bearing pad and the radial loads acting on the pad propagate through the pivot pin. New pivot pins were purchased and equipped with strain gauges. The new pivot pins were calibrated and a transfer function between applied load and measured output voltage was identified for each pivot pin. After calibration the pivot pins were installed in a vertical hydropower unit. Measurements were performed for several different operating modes of the hydropower unit. To verify that the measured load levels were of right order of magnitude, the radial bearing loads were calculated from numerical simulations of bearing properties and shaft eccentricity measurements. The two methods for determining bearing load showed almost the same results. This indicates that either method can be used to determine bearing load.     

电沉积方式对纳米晶钴镀层的结构和摩擦学性能影响研究

采用不同电沉积方式制备了不同结构和晶粒尺寸的纳米晶钴(Co)镀层.采用扫描电镜和X-射线衍射仪分别分析了镀层表面形貌、晶相结构与晶粒尺寸.采用MV-2T显微硬度计测试镀层的硬度.最后采用UMT-3M多功能摩擦磨损试验机对镀层的摩擦和磨损性能进行了评价,并用扫描电镜对其磨损表面进行了观察分析.结果表明:电沉积方式对制备的纳米Co镀层的晶相结构、晶粒尺寸、镀层形貌和摩擦磨损性能影响显著;采用双脉冲制备的纳米Co镀层具有最小的晶粒尺寸、最高的硬度及较好的耐磨性能;采用单双脉冲混合电镀制备的纳米Co镀层表面针孔孔洞直径最小,结构最致密,耐磨性能最好.这些研究结果说明可通过优化电沉积方式来提高镀层的结构致密性,改善其硬度和耐磨性能.     

汽车发动机用窄型链的多冲磨损特性研究

为了提高国产机油泵链条的性能,满足发动机轻量化的个性需求,通过发动机总成试验,研究了一种窄型的汽车发动机机油泵链06BN-1的磨损机制,并对套筒和销轴的磨损表面进行微观分析.结果表明,汽车发动机机油泵链的主要磨损形式为疲劳磨损,销轴?套筒零件表面的裂纹生成?扩展与剥落是其主要磨损失效机制.销轴和套筒零件均发生循环软化,滚子零件发生循环硬化.微动磨损是汽车链＂散架＂失效的重要原因之一.保证滚子零件具有足够的强度与塑性,并采取合理的成形工艺,是提高滚子零件多冲抗力的有效方法     

油溶性烷氧基硼酸钠的制备及其抗磨减摩性能研究

合成了油溶性烷氧基硼酸钠,用红外光谱（IR）和等离子体原子吸收光谱（ICP）表征其结构与组成,在四球及环块摩擦磨损试验机上考察了其摩擦学性能,采用扫描电子显微镜（SEM）及光电子能谱仪（XPS）观察分析磨斑表面成分。结果发现：所合成的油溶性含硼和钠的化合物在磨斑表面形成由FeB,Fe2B和沉积物等组成的抗磨减摩膜,从而显著改善油品的抗磨减摩性能。     

摩托车传动用滚子链磨损特性的研究

道路行驶磨损试验结果表明，摩托车传动用滚子链套筒和销轴零件的主要磨损形式是磨粒磨损，并伴随有疲劳磨损的特征．由微观分析和链条的磨损伸长量可知：套筒和销轴的初始表面硬度较高，有利于改善其磨损表面形貌状态和耐磨性；在磨粒磨损机制下，套筒和销轴零件的表面硬度较低，容易产生“犁切”，表面层的循环硬化现象比较明显，磨损严重；在油池润滑条件下，套筒和销轴零件的表面硬度较高，裂纹的扩展速率较快，循环软化现象也较明显，当表面硬度较低时发生循环硬化．循环软化与循环硬化是导致磨损严重的原因之一．     

O形橡胶密封圈摩托车滚子链磨损特性的研究

对 O形橡胶密封圈摩托车滚子链和普通滚子链进行了 6 0 0 0 km道路和 30 0 h台架磨损对比试验 ,分析了磨损表面形貌 .结果表明 :O形圈滚子链比普通滚子链的耐磨性能高 ,寿命长 ;O形圈链条中销轴和套筒的磨损主要以疲劳磨损为主 ,并伴随着粘着磨损 ;链板和 O形圈的磨损为疲劳磨损 ;而普通链条销轴和套筒的主要磨损形式是磨粒磨损 ,并伴随着疲劳磨损 .链条中铰链摩擦副 (销轴和套筒 )的磨损表面产生的循环硬化有利于提高耐磨性 .     

45钢/PA66配副干滑动摩擦磨损性能研究

采用45钢销和尼龙PA66盘,运用正交试验法在MMW-1A万能摩擦磨损试验机上研究干滑动摩擦条件下速度、载荷和金属销表面粗糙R_a对45钢/PA66配副摩擦学性能的影响. 通过极差分析与方差分析发现:载荷、粗糙度对摩擦系数与磨损量有显著影响,而速度影响相对较小. 当载荷为50 N,速度为11.25 m/s,R_a为0.60 μm时,摩擦系数与磨损量最小. 基于正交试验的最优结果,开展控制变量试验,试验结果表明:载荷小于90 N时,PA66以黏着磨损为主;载荷为90 N时,PA66磨损形式为犁削磨损和黏着磨损. 载荷为140 N时,PA66的磨损形式为黏着磨损并伴有胶合现象的产生. R_a小于0.46 μm时,PA66以黏着磨损为主;R_a为0.46 μm时,PA66的磨损形式为黏着磨损和犁削磨损且在对偶金属销表面上形成连续的转移膜;R_a大于0.46 μm时,PA66以犁削磨损为主.      

聚酰胺酰亚胺/聚四氟乙烯复合涂层的制备及其摩擦学性能和耐腐蚀性能

制备了具有良好摩擦学性能和优异耐腐蚀性能的聚酰胺酰亚胺/聚四氟乙烯(PAI/PTFE)多功能复合涂层. 采用CSM摩擦磨损试验机评估了涂层的摩擦学性能,采用P4000A电化学工作站研究了PAI/PTFE复合涂层在质量分数为3.5% NaCl溶液中的抗电化学腐蚀性能. 重点研究了PTFE与PAI的固体质量比对涂层摩擦学性能和耐腐蚀性能的影响. 结果表明:适量PTFE的引入极大增强了PAI涂层的摩擦学性能和耐腐蚀性能. 特别是,当PTFE与PAI的固体质量比为0.6时,涂层的摩擦学性能最佳,摩擦系数为0.075,磨损率为3.72×10-6 mm3/(N·m). 当PTFE与PAI的固体质量比为1时,复合涂层在质量分数为3.5%的NaCl溶液中浸泡240 h后涂层的低频阻抗值∣Z∣_{0.01 Hz}高达3.83×109 Ω?cm2,仍表现出较好的耐腐蚀性能. 此外,经过240 h中性盐雾试验,复合涂层表面没有出现起泡、生锈等现象. 复合涂层具有如此优异的摩擦学性能和耐腐蚀性能归因于PTFE优异的润滑性能以及涂层对腐蚀介质阻隔性能的增强.      

氮气气氛条件下钢/铜摩擦副的摩擦磨损特性研究

利用MMS-1G型销-盘式高温高速摩擦磨损试验机研究了氮气气氛条件下CrNiMo钢/H96黄铜配副的摩擦磨损特性,利用扫描电子显微镜观察磨损表面形貌,采用能谱仪分析磨损表面及其磨屑的主要元素成分,并分析其磨损机理.结果表明:在氮气气氛条件下,摩擦系数随滑动速度和载荷(pv值)增加而减小;磨损率随pv值增加而增大;在逐步增加pv值的过程中,其磨损机制由粘着磨损转变为磨粒磨损和粘着磨损共同作用.     

织构化表面NbSe2涂层的真空载流摩擦学行为

针对航天器滑动电接触部件特殊的真空载流服役要求,利用建立的真空载流摩擦试验平台,探索铜基材织构化表面喷涂NbSe₂涂层作为空间新型导电润滑材料的可能性.研究条状和网状不同织构以及各自在不同织构密度条件下喷涂NbSe₂涂层的真空载流摩擦学性能和影响作用规律;对比现役电镀金涂层,探讨其在真空载流条件下摩擦学和电接触行为优势.结果表明：网格状较条状织构表面喷涂NbSe₂涂层的载流摩擦学性能更好,而且随织构密度的增加,减摩耐磨性能得到提高.织构间距为200μm的网格状织构表面喷涂的NbSe₂涂层展现出最佳的真空载流摩擦学性能.相较于现役的金电镀层,其在真空载流摩擦条件下展现出更加优异的摩擦学和电接触性能,摩擦系数由0.25降至0.05,接触电压与现役材料处于同一量级,电噪音波动明显改善,由0.09V降至0.04V.     

Forced convective heat transfer enhancement with perforated pin fins

Increasing miniaturization of high speed multi-functional electronics demands ever more stringent thermal management. The present work investigates experimentally and numerically the use of staggered perforated pin fins to enhance the rate of heat transfer in these devices. In particular, the effects of the number of perforations and the diameter of perforation on each pin are studied. The results show that the Nusselt number for the perforated pins is 45 % higher than that for the conventional solid pins and it increases with the number of perforation. Pressure drop with perforated pins is also reduced by 18 % when compared with that for solid pins. Perforations produce recirculations in the x–y as well as the x–z planes downstream of the pins which effectively increase convective heat transfer. However, thermal dissipation decreases significantly when the ratio of pin diameter to perforation diameter exceeds 0.375. This is due to both a reduction in the number of perforation per pin and the decrease in the axial heat conduction along the pin.